Enclosed Ground Flare Installation for Producer Gas

Client - Schlumberger for Cairn India Limited

  • Location: Rajasthan, India

  • Type: Global Open Tender

  • Year of Supply: 2021

  • Scope: Complete Design, Engineering, Fabrication, Supply, and Commissioning of Enclosed Ground Flare System at Barmer

  • Result: CRA successfully executed this project


Situation

In this greenfield project, the client wanted a Pollution Control Equipment for a very lean gas (Hydrocarbon less than 10%). The location also required this project to have a low environmental impact and effective use of space. This meant low atmospheric pollution, zero radiation at the ground level, and ability to safely use the area surrounding the flare.

Capacity: 17,000 M3/Hr.

Medium: Producer Gas


Action

CRA proposed the use of our custom design Enclosed Ground Flare for this application. Due to the lean input gas, this Enclosed Ground Flare can also be considered as a Thermal Oxidizer with minimal requirements of power, fuel, space, and maintenance.


The requirement of continuous combustion with lean gasses rich in Carbon Dioxide (CO2), high fluctuations in flow rate, extreme environmental conditions (in desert area) and rigorous safety standards necessitated extensive research and development to meet the challenging requirements of this project.


Our structured approach to our projects, inclusive of project management, reviewed and validated designs, and extensive collaboration with the client are outlined below.


CRA engineered the following:


Process Design

  • Sizing and Design of Combustion Chamber

  • Selection of Burners and Flame Front Generator Ignition Pilots

  • Sizing and Design of all Piping and Valves

  • Specification of Instrumentation and Control Requirements

  • Specification of Refractory Material and Anchoring System

  • Specification of Flame Arrestors, Water Seal, and Knockout Drum

  • Designed as per API 521 and API 537

  • Generation of all Drawings and Documentations

Manufacturing

  • Combustion Chamber and Refractory Lining

  • Burners and Staging

  • Pilot Burner and Ignition System

  • Electronic Ignition Control Panel

  • Knockout Drum

  • Water Seal

  • Factory Acceptance Testing


Installation and Commissioning

  • Site Acceptance Testing


Result

CRA’s involvement in this process led to a seamless experience for the client with all aspects of the project being extremely well integrated, and all challenging requirements being met. The client’s challenges with environmental impact of flaring were solved with the Totally Enclosed Ground Flare.


We take pride in providing such solutions that have a significant impact on the environment. Our design and engineering processes keep aspects such as meeting and exceeding environmental norms at the top of our agenda and we use this mission to drive all our decisions.


With CRA’s end-to-end solutions, the client can be sure that we will deliver.


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